Anti-telescoping adhesive tape product

ABSTRACT

An adhesive tape product comprises a length of adhesive tape mounted on a core with a reduced tendency to telescope. A layer of compressible foam is provided between the core and the body of tape wound on the core. Alternatively, the core is fabricated to have a slight bulge in its center giving the core a barrel shape thereby reducing the tendency for the body of tape wound upon the core to telescope.

[0001] The present invention relates to adhesive tape products in whicha body of adhesive tape, normally comprising an acetate or plastic filmwith adhesive on one or both sides, is wound upon a cylindrical tapecore. The tape product is sold alone or as part of a dispenser andallows the user to have a body of tape in a convenient, compact form anddispense selected lengths from that tape product for use.

BACKGROUND OF THE INVENTION

[0002] Adhesive tape products, primarily pressure sensitive adhesivetape products, are used in a wide variety of applications. Oneparticularly high volume application is household and stationery use,transparent adhesive tape, that is a transparent acetate or plastic filmhaving an adhesive coated on one side, is used in offices and householdsin a number of applications. Such tapes come in various widths including½ inch, ¾ inch, 1 inch, and 2 inches. Metric widths including 12 mm and19 mm are also common. The transparent tape is often wound upon acylindrical core. The core has a width generally equal to the width ofthe tape. The tape core often has one of several inside diametersincluding ½ inch, 1 inch and 3 inches. Various lengths of tape are woundupon these cores. Common tape lengths and are 300 inches to 36 yards.Lengths can be 60 yards and more.

[0003] The above-described adhesive tape products are sold in very largenumbers and therefore must be manufactured in automated facilitiesproducing a uniform high quality product.

[0004] One method of manufacturing such products is to create a broadlong roll of adhesive coated film, slit this film to the appropriatewidth, and wind appropriate lengths of the slit film onto tape cores.Some cores are large diameter (3 inch) paper tubes upon which the lengthof tape is wound. Another core consists of two thin plastic coaxialcylinders spaced coaxially about ⅛ inch apart with a central thin axialwall connecting the two thin plastic cylinders. This double-walledplastic core is often seen as a one inch diameter core used with ¾ inchtape sold for use in the office or home environment.

[0005] One problem encountered with adhesive tape products of the typedescribed is called “telescoping.” In a roll of tape which suffers fromtelescoping, successive layers of the adhesive tape wound upon the coreare displaced axially. Thus, the roll of tape takes on a generallyconical shape rather than the cylindrical shape of a tape product notsuffering from telescoping. A roll of tape suffering from a severe caseof telescoping often cannot be mounted on a dispenser. Moreover, such aroll of tape has the edges of the adhesive of succeeding tape layersexposed and can pick-up dirt. A significantly telescoped adhesive tapeproduct will be viewed as defective and not purchased. Telescoping ismore of a problem with narrow width tapes when compared to wider tapes.Telescoping is more of a problem on smaller diameter tape cores whencompared to larger diameter tape cores.

[0006] Adhesive tape products are often used in dispensers. The adhesivetape wound upon a core must be easily loadable upon a dispenser and alsooperate smoothly when a consumer wishes to apply a length of tape fromthe dispenser to a workpiece.

[0007] Small size is sometimes an advantage with respect to adhesivetape products. Thus, smaller diameter cores are sometimes used in aneffort to minimize overall package and dispenser size. The core in anadhesive tape product must work smoothly in such a small dispenser.

[0008] In addition to its function of holding tape to be dispensed inthe retail package, the tape core also performs a function in themanufacturing operation creating the product. After a sheet ofadhesive-coated film is slit into appropriate widths for tape, the slitfilms must be wound into a finished product. The film is generally woundupon the tape core. The tape core must cooperate with the manufacturingapparatus in a way which allows it pick up the leading edge of the slitfilm, and wind it onto the core itself into a uniform non-telescopedproduct.

[0009] There is a need for adhesive tape products which do not telescopeespecially in the smaller sizes.

SUMMARY OF THE INVENTION

[0010] The present invention contemplates a new and improved piece oftape product less prone to telescoping, especially in the smaller sizes,which is inexpensive to manufacture, operates smoothly withmanufacturing equipment and operates smoothly in dispensers, especiallyin the smaller sizes.

[0011] In accordance with the present invention, an adhesive tapeproduct comprises a hollow, generally cylindrical core surrounded by acompressible foam strip which is in turn surrounded by a length ofadhesive tape.

[0012] Further in accordance with the invention, the total thickness ofthe foam strip surrounding the core is about 40 mils (1 mm).

[0013] Yet further in accordance with the invention, the principal foamstrip completely surrounds the core in one turn and one turn only.

[0014] Yet further in accordance with the invention, an adhesive tapeproduct comprises a tape core which is hollow and generally cylindricalwith an outer surface bulging outwardly at its center whereby said tapecore has a barrel shaped appearance and said tape core is wound with alength of tape forming an adhesive tape product.

[0015] Still further in accordance with the invention, an adhesive tapeproduct is provided comprising a barrel shaped tape core surrounded by alayer of foam material which is in turn surrounded by a body of adhesivetape wound in several windings around said tape core and foam strip.

[0016] It is the principal object of the present invention to provide anew and improved adhesive tape product which is inexpensive tomanufacture, operates smoothly with dispensers, and has a low tendencyto telescope.

[0017] It is another object of the present invention to provide anadhesive tape product having a very small tape core, carrying arelatively large amount of tape yet having a low tendency to telescope.

[0018] It is still another object of the present invention to provide anadhesive tape product which will have a low tendency to telescope yetwhich will operate smoothly in small hand-held dispensers.

[0019] These and other objects and advantages of the present inventionwill become apparent from the following detailed description of thepreferred embodiments thereof and from the accompanying drawings inwhich:

[0020]FIG. 1 is a side elevation view of an adhesive tape product inaccordance with the present invention;

[0021]FIG. 2 is a perspective view of the tape core seen in FIG. 1;

[0022]FIG. 3 is a side elevation view of the adhesive tape products seenin FIG. 1 fully unwound showing the core and inner end of the tapeproduct only;

[0023]FIG. 4 is a top view of the tape product seen in FIG. 3;

[0024]FIG. 5 is a bottom view of the tape product seen in FIG. 3;

[0025]FIG. 6 is a perspective view of an alternative tape core usable inthe present invention;

[0026]FIG. 7 is a side elevation view of an adhesive tape product usingthe tape core seen in FIG. 6;

[0027]FIG. 8 is a side elevation view of a second adhesive tape productin accordance with the present invention using the tape core of FIG. 6;

[0028]FIG. 9 is a side elevation view of an adhesive tape product inaccordance with another embodiment of the present invention;

[0029]FIG. 10 is an enlarged cross-sectional view of a tape core seen inFIG. 9 with the end portion of the tape still attached to the tape core;and,

[0030]FIG. 11 is a further enlarged segment of the tape core seen inFIG. 10.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0031] Referring to the drawings wherein the showings are for thepurposes of illustrating preferred embodiments of the invention and notfor the purpose of limiting same, FIG. 1 showed a front elevation viewof an adhesive tape product 10 in accordance with the present invention.A tape core 12 is surrounded by a foam layer 14 which is in turnsurrounded by a multitude of turns of adhesive tape 16. Referring toFIG. 2, the tape core 12 also seen in FIG. 1 is shown isolated from theother elements of the invention. The tape core is approximately 0.5 inch(12 mm) wide and is a hollow cylinder. The inside diameter of thecylinder is approximately 0.5 inch (12 mm) and the outside diameter ofthe cylinder is approximately 0.64 inch (16 mm). The inside surface 18of the core is generally cylindrical, continuous and smooth. The outsidesurface of the core 22 is likewise generally cylindrical, continuous andsmooth. The edges where the outside surface 22 and the inside surface 18meet the ends of the cylinder are radius providing a non-sharp corner.The tape core 12 is solid and sized and finished to work reliably withsmall tape dispensers such as that available from Manco, Inc. of Avon,Ohio.

[0032]FIG. 3 shows the elements of the adhesive tape product 10completely unrolled. The adhesive tape 16 (not shown in its entirety) isin excess of 30 feet long. The first portion of the adhesive tape 16 isa leader portion 24 which adheres directly to the outside surface 22 ofthe tape core 12. The leader is about 0.7 inches (18 mm) long.Immediately following the leader, is a foam support portion of the tape26. The foam support portion of the tape is adhered to the foam layer14. The foam support portion 26 for use with the ½ inch tape coredescribed above is approximately 2.24 inches (57 mm) in length. Thisprovides for one complete turn immediately adjacent the tape core 12 asseen in FIG. 1. Of course, for different size tape cores, differentlength foam support portions 26 would be used. Immediately adjacent thefoam support portion of the tape 26 is the usable tape portion 30. Theusable tape portion is the portion of the tape available for use by theconsumer and, in the side illustrated in the drawings is in excess of 33feet (10 meters) long.

[0033] The foam layer 14 is the same width as the adhesive tape 16 andthe same length as the foam support portion 26 of the adhesive tape 16.The foam layer 14 is approximately 40 mils (1 mm) thick and iscompressible. Any foam material which is chemically stable with theadhesive tape 16 and is compressible is appropriate.

[0034] The leader portion 24, foam support portion 26 and usable tapeportion 30 of the adhesive tape 16 are all part of a continuous strip ofadhesive tape having a uniform width and characteristics. Adhesive isapplied over one entire side of the adhesive tape 16 including theleader portion 24, the foam support portion 26 and the usable tapeportion 30. The foam layer 14 can be either completely non-adhesive orslightly adhesive without interfering with its ability to preventtelescoping. Printing can be placed upon the adhesive tape 16 on any ofthe three portions as desired. Alternatively, all three portions orselected ones of the three portions, leader 24, foam support 26, andusable tape portion 30, can be left transparent, colored or otherwisedecorated.

[0035]FIG. 4 illustrates a top view of the unwound tape product as seenin FIG. 3 showing the continuous nature of the adhesive tape 16 and itsthree portions, the leader portion 24, the foam support portion 26, andthe usable tape portion 30. FIG. 5 is a bottom view of the unrolled tapeas seen in FIG. 3 and illustrates the placement of the foam layer 14 onthe adhesive tape 16.

[0036] The adhesive tape product 10 is manufactured by winding theadhesive tape 16 with the foam layer 14 attached on the core 12. Theleader 24 first contacts the outside surface 22 of the core 12 and isadhered to the core 12. The foam layer 14 next engages the outsidesurface 22 of the core 12 and is wound one complete turn around the core12. This results in the core 12 being surrounded by the foam layer 14 asseen in FIG. 1. The usable tape portion 30 is then wound around the foamlayer 14. The usable tape portion 30, being significantly longer thanthe other portions, requires a multitude of turns around the tape core,usually in excess of 100. Winding of the tape upon the core must beperformed quickly in order to produce an economically attractiveproduct. Tension is used in this winding process. This tension can varyfrom product to product and within a particular product as the tapeprogresses from small turns near the core to larger turns near the endof the usable tape portion 33. This tension may induce forces whichencourages telescoping. Applicant has found that the application of alayer of foam as described above counteracts the tendency to telescopeand significantly lessens the tendency of the tape product to telescopeat the time of manufacture or thereafter.

[0037] An alternate tape core 52 usable in the invention is shown inFIG. 6. The alternate tape core 52 has a generally smooth continuouscylindrical inside surface 54. The alternate tape core 52 has a outsidesurface 56 which is generally smooth, continuous and somewhatbarrel-shaped. The axial center 58 of the outside surface 56 is somewhatlarger in diameter than the axial ends 62, 64 of the alternate tape core52. The central swelling is very slight. For example, the outer diameterof the tape core 52 at the axial center may be 0.66 inches (16.75 mm)and the outside diameter of the tape core 52 at the axial ends 62, 64may be 0.62 inches (15.75 mm). The outside surface 56 is generallysmooth and continuous providing a very gentle barrel shape. Thisbarrel-shaped tape core can be used as an element of tape product 70incorporating the alternate core 52, a 40 mils (1 mm) foam layer 72, anda long length of adhesive tape 74 as seen in FIG. 7. It has also beenfound that the alternate tape core 52 can be wound directly with anadhesive tape 72 to form an adhesive tape product 80. The barrel-shapedalternate tape core 52 provides increased resistance to telescoping evenwithout use of the foam layer 72.

[0038] Another embodiment of the invention is shown in FIGS. 9, 10 and11. An adhesive tape product 100 comprises a cylindrical tape core 102and a length of adhesive tape 106. The tape core is shown enlarged inFIG. 10. A segment of the tape core is shown further enlarged in FIG.11. The tape core 102 comprises an inner solid layer 132 and an outerfoam layer 134. The inner solid layer 132 has a smooth, hard cylindricalinner surface which will operate well with tape dispensers. The outerfoam layer 134 is somewhat compressible and performs the same functionas the foam layer 14 seen in the first embodiment of the invention. Theouter foam layer in the embodiment of FIGS. 9-11 however is part of thetape core. This can be achieved by overmolding a foam layer onto a solidcylindrical inner layer 132. Alternatively, the foam layer 134 can be afoam tube slid onto a solid core. The foam layer 134 can be created byother means in which a plastic is extruded or otherwise formed into acylindrical shape and differentiates into a solid inner portion 132 anda compressible foam outer portion 134.

[0039] The tape core illustrated in FIGS. 10 and 11 is advantageous inthat the manufacturing process used to apply the tape 106 to the corecan be identical to that used with prior art tape products. There is noneed for application of a foam strip to the tape core in the windingprocess. The foam layer is already part of the tape core assembly uponwhich the tape is wound.

[0040] The invention has been described with reference to preferredembodiments. Moreover, the invention has been described with oneparticular size of tape product as illustrative. The invention is usefulin other size adhesive tape products but appears to have most benefitwith small core diameter, long narrow tape products. Obviously changesin size, other modifications and other alternations will occur to othersupon the reading and understanding of the specification. It is intendedto include all such modifications and alterations insofar as they comewithin the scope of the appended claims or the equivalents thereof.

Having thus described the invention, it is so claimed:
 1. An adhesivetape product comprising: a hollow cylindrical core having a diameter anda width and an outer surface; a compressible foam strip surrounding saidcore; and, a length of adhesive tape having a uniform width and a lengthsubstantially greater than said width wound in several turns about saidcore and said foam strip.
 2. The adhesive tape product of claim 1,wherein said foam strip is about 40 mils (1 mm) thick.
 3. The adhesivetape product of claim 1, wherein said foam strip surrounding said corehas a total thickness of about 40 mils (1 mm).
 4. The adhesive tapeproduct of claim 1, wherein said foam strip surrounds said core in asingle layer and said foam strip is about 40 mils (1 mm) thick.
 5. Theadhesive tape product of claim 1, wherein said core comprises a thinsolid tubular wall.
 6. The adhesive tape product of claim 5, whereinsaid core has an outer surface bulging outwardly near the core's axialcenter giving said core a slight barrel shape.
 7. An adhesive tapeproduct comprising: a tape core having an axial width, said core beinghollow with a solid, generally cylindrical outer wall, said outer wallhaving an outer surface which bulges outwardly at its axial centergiving said core a slight barrel shape; and, a length of adhesive tapehaving a uniform width and a length substantially greater than saidwidth wound in several turns about said core.
 8. The adhesive tapeproduct of claim 7, additionally comprising a compressible foam stripsurrounding said core and surrounded by said length of adhesive tape. 9.The adhesive tape product of claim 8, wherein said foam strip is about40 mils (1 mm) thick.
 10. The adhesive tape product of claim 9, whereinsaid foam strip has a generally uniform width approximately equal tosaid adhesive tape width and surrounds said core in a single layer. 11.An adhesive tape product comprising: a hollow cylindrical core having adiameter and a width, a solid inner layer, a foam outer layer, and anouter surface; and, a length of adhesive tape having a uniform width anda length substantially greater than said width wound in several turnsabout said core.
 12. The adhesive tape product of claim 11, wherein saidfoam layer is about 40 mils (1 mm) thick.
 13. The adhesive tape productof claim 11, wherein said core inner layer comprises a thin solidtubular wall.
 14. An adhesive tape product comprising: a tape corehaving an axial width, said core being hollow with a solid, generallycylindrical inner surface and a foam layer; and, a length of adhesivetape having a uniform width and a length substantially greater than saidwidth wound in several turns about said core.
 15. The adhesive tapeproduct of claim 14, wherein said foam layer is about 40 mils (1 mm)thick.